Zener barriers - operating instructions
Operating principle
1 Zener barriers - operating instructions
Application
Zener barriers are used in control and instrumentation
systems for the processing of standardised signals, such as
20 mA and 10 V. Zener barriers contain intrinsically safe
circuits that are used to drive intrinsically safe field devices
within hazardous areas. The manufacturers data sheets
must be consulted.
The relevant regulations and directives governing the
intended application must be observed.
Installation, commissioning
Zener barriers are constructed to a protection classification
of IP20 and accordingly must be appropriately protected
from adverse conditions such as splashing water and soiling
in excess of pollution severity 2.
Zener barriers must be installed outside the hazardous area!
Only those circuits identified as intrinsically safe may be
located within the hazardous area.
When intrinsically safe field devices are interconnected with
the intrinsically safe circuits of the related Zener barriers, the
respective highest values (safety parameters) for the field
devices and the Zener barriers - in the sense of explosion
protection - must be observed (demonstration of intrinsic
safety). The EU certificate of conformity or EU prototype test
certificate must be followed. Particular importance is
attached to maintaining the "Special conditions" contained
in these certificates.
When intrinsically safe circuits are employed in an explosive
dust atmosphere (zones 20 and 21), only appropriately
certificated field devices are permitted to be incorporated.
1.1 Operating principle
The Zener diodes in the barriers are connected in the reverse
direction. The breakdown voltage of the diodes is not
exceeded in normal operation.
Hazardous area Safe area
Resistor Fuse
R1 F1
Zener diodes
ZD1 ZD2 ZD3
Figure 1.1 Circuit diagram
If this voltage is exceeded, due to a fault in the non-Ex-area,
the diodes start to conduct, causing the fuse to blow, thus
preventing the transfer of unacceptably high energy into the
hazardous area.
Terminals 7 and 8 are connected to the devices in the non-
hazardous area. The single condition that these devices must
satisfy, is that they must not contain a source whose potential
relative to earth is greater than 250 V/253 Veff AC or 250/
253 V DC.
Subject to reasonable modifications due to technical advances.
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Installation and commissioning within zone 2
The devices must be installed in switch boxes or distributor
boxes to protection category IP54 or better.
The devices may be installed within zone 2. Only those
circuits identified as intrinsically safe are permitted to be
installed in zone 1 or zone 0 and in accordance with their
ignition protection category approval. The actual installation
of the intrinsically safe circuits is to be carried out in
accordance with the applicable installation regulations.
When interconnecting intrinsically safe field devices with the
intrinsically safe circuits of the associated Zener barriers,
the respective highest values (safety parameters) of the field
device and the associated device, in the sense of explosion
protection, must be taken into account (demonstration of
intrinsic safety). The conditions stated on the EU certificates
of conformity or EU prototype test certificates must be
observed.
In addition, for operation within zone 2, the statements of
conformity of the certifying authorities/declarations of
conformity of the manufacturer must be observed. Particular
importance is attached to maintaining the "Special
conditions" contained in these certificates.
When intrinsically safe circuits are employed in an explosive
dust atmosphere (zones 20 and 21), only appropriately
certificated field devices are permitted to be incorporated.
Servicing and maintenance
The transmission characteristics of the devices remain stable
over long periods, so that regular adjustments or other
precautions are not required. This also means that no
maintenance work is required.
Fault elimination
No modifications may be made to devices that are operated in
connection with hazardous areas. Repairs must only be carried
out by specially trained and authorised personnel.
Terminals 1 and 2 are connected to the intrinsically safe
circuits in the hazardous area. If they are used in the
hazardous area, active intrinsically safe apparatus must be
certificated unless the electrical values of such apparatus do
not exceed any of the following values: 1.5 V; 0.1 A; 25 mW.
Pepperl+Fuchs Zener barriers are identified in terms of
voltage, resistance and polarity, e. g. 10 V, 50 Ohm, positive
polarity. These figures correspond to the Zener voltage Uz and
the total resistance of all barrier components. They therefore
represent the safety values. The values stated on the type
identification label correspond to the "worst case" data for
Uz (Uo) and Ik (Io) determined during certification.
Ik is obtained by dividing Uz by the resistance R1. It should be
noted once again, however, that these values do not
correspond to the operating range of the Zener barrier.
Ideally, Zener diodes would not allow any current in the reverse
direction until the Zener voltage has been attained. In practice,
Zener diodes do allow a small leakage current, the value of
which increases as the applied voltage is increased.
05/23/03
Date of issue
Copyright Pepperl+Fuchs, Printed in Germany

The operating range of a Zener barrier must therefore be such
that it is below the Zener voltage, so that the leakage current is
restricted to a minimum. Zener barriers are normally tested to
ensure that at the prescribed voltage the leakage current is
smaller than 10 A.
Hazardous area Safe area
50 mA (+)
Load 10 A 24 V
Power
supply
(-)
Figure 1.2 This figure shows a selection of leakage currents through
the Zener barriers under normal circumstances. The
Zener barriers conduct a maximum of 10 (1) A leakage
current so long as the supply voltage is less than 25.5 V.
This is normal and has very little effect on the load. If the
voltage exceeds 25.5 V, the Zener diodes start to
conduct more current. This can have an effect on the
operating current and the accuracy. It is therefore
recommended that a controlled voltage source be used,
which maintains the voltage under the value at which the
diodes will start to conduct.
(A 24 V, 300 Ohm barrier is represented here as an
example)
Pepperl+Fuchs Zener barriers have a low series resistance,
given by the sum of the resistance R1 and the resistance value
of the fuse F1. Due to the low series resistance, an inadvertent
short-circuiting of terminals 1 and 2 can cause the fuse to blow.
In order to avoid this, some barriers are available with
electronic current limitation (CL-version).
If the Zener barriers are provided with a resistance, this limits
the short-circuit current to a safe value in the event of a short-
circuit of the connecting wiring in the hazardous area or a
connection to earth of the wiring attached to terminal 1, as the
fuse blows.
Many barriers are available with a resistance connected
between the output terminals. These are used in
4 mA 20 mA transmitter circuits. The resistance converts
the current in the intrinsically safe circuit into a voltage that can
be measured in the safe area.
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Zener barriers - operating instructions
Operating principle
These voltages are stated in the data sheet for a given barrier,
together with the leakage current. If the leakage current for a
given voltage differs from 10 A, this is specifically stated.
Hazardous area Safe area
50 mA (+)
Power
25.5 V Load 24 V supply >25.5 V
(-)
Figure 1.3 This figure shows that if the maximum permissible input
(supply) voltage is exceeded, the total current drains
through the Zener diodes, without reaching the explosive
surroundings.
Pepperl+Fuchs Zener barriers can be used in many
applications. In the simplest case, a single channel barrier with
a ground connection is used. But in many applications it is not
desirable that the intrinsically safe circuit is connected directly
to ground. If the circuit in the safe area is grounded, under
some circumstances grounding of the intrinsically safe circuit
can lead to faults within the system. In this case, quasi ground-
free intrinsically safe circuits can be constructed with two or
more barriers. This floating circuitry can be simply achieved
with 2- or 3-channel barriers.
Double grounding of intrinsically safe circuits is not permitted.
The insulation voltage of the wiring and field devices,
measured with respect to ground, must be greater than
500 V AC. The permissible ambient temperature of the Zener
barriers is between -20 C 60 C.
Copyright Pepperl+Fuchs, Printed in Germany
2
 Zener barriers - operating instructions
Multi-channel barriers

1.2 Multi-channel barriers

Analogue circuits are often connected to two-channel barriers
(see Figure 1.5). Since there is no grounding on this type of
circuit, the system is a quasi floating one. It is termed "quasi
floating", because it is "one Zener voltage" above the ground
potential. Although it does not actually float, the signal-to-noise
ratio is improved.
A further advantage of multi-channel Zener barriers is that a
higher packing density can be achieved.
.

Hazardous area Safe area

Hazardous area Safe area

4 mA ... 20mA
4 mA ... 20mA transmitter (+) 24 V
transmitter
(+) 24 V

RM
RM
Power supply can
not be grounded.

Figure 1.4 Single-channel Zener barrier Figure 1.5 Two-channel Zener barrier

1.3 Grounding of Zener barriers

Intrinsically safe circuits with Zener barriers without galvanic
isolation must be grounded. The cross-section of the ground
connection, using a copper conductor, must be at least 4 mm2
(for further details see EN 60079-14, section 12.2.4). The
maintenance of these requirements prevents the occurrence of
a dangerous potential with respect to ground.
A fault of the type illustrated in figure 8.6 can cause a
dangerous spark if the Zener barrier is not grounded, but
grounding is provided via the field device in the intrinsically
safe circuit (Figure 1.5). If a potential occurs in the fault case,
which is higher than permitted (see Figure 1.6) the Zener
diodes become conducting and the current is conducted away
via the ground. The fuse "blows".
.

Hazardous Safe area Hazardous Safe area

area Fault area Fault

Power supply Power supply

AC/DC
supply
voltage
Hazardous potential
Hazardous potential

Transformer Transformer

Fault current
Intrinsically
safe ground

Figure 1.6 Non-grounded Zener barrier Figure 1.7 Grounded Zener barriers
The system must have its own independent ground
conductor, through which no supply system current
flows.
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 Zener barriers - operating instructions
Installation notes

1.4 Installation notes

Pepperl+Fuchs Zener barriers in the Z7, Z8 and Z9 series can Pepperl+Fuchs Zener barriers also feature a space-saving
be mounted on a standard rail to EN 50022 in 3 different 12.5 mm housing which incorporates up to 3 channels.
arrangements.
12.5 110
Equipotential bonding via the standard rail (grounding of all
snapped-on Zener barriers)
Insertion strip
ZH-ES/LB

Label carrier
ZH-Z.BT

DIN rail NS 35/7.5

115
35 mm standard rail
to DIN EN 50 022

Clamp
ZH-Z.USLKG5

Figure 1.11 Mechanical features

Figure 1.8 Equipotential bonding via the standard rail
Construction: Modular terminal housing in Makrolon,
Group grounding through insulated mounting flammability classification UL 94: V -0
Fixing: Snaps onto 35 mm standard rail to DIN EN 50022
Connection options: Self-opening terminals, max. core cross-
section 2 x 2.5 mm
The barriers are usually installed in racks or control cabinets.
They can be built into housings under production conditions,
with the proviso that the housing must afford adequate
protection. They can also be employed in hazardous areas,
when it has been ascertained that the housing has been
certificated for this purpose.
The installation must be carried out in such a way that the
intrinsic safety is not compromised by the following factors:
Danger of mechanical damage
Mounting block
Non-authorised changes or influence exerted by external
ZH-Z.AB / NS personnel
Humidity, dust or foreign bodies
Figure 1.9 Insulated mounting (Individual grounding)
Ambient temperature exceeding the permissible level
Individual grounding through insulated mounting The connection of non-intrinsically safe circuits to
intrinsically safe circuits
Grounding of the mounting rail is of the normal type, i. e. both
ends are connected to the intrinsically safe ground. This also
simplifies checking the grounding.
Many installations provide the option of subsequent expansion.
Replacement cable for this purpose can be connected to the
Mounting block
ZH-Z.AB/SS Z799 dummy barrier and unused cable can be connected to
Single socket
N-Combined rail the intrinsically safe ground.
ZH-Z.NLS-Cu3/10
ZH-Z.ES

Connector for
ground lead
ZH-Z.AK4

Connector Ground rail feed

ZH-Z.AK16 ZH-Z.LL
Spacing roller
ZH-Z.AR.125

Figure 1.10 Insulated mounting (Individual grounding)

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 Zener barriers - operating instructions
Zener barrier specifications
1.5 Zener barrier specifications
Nominal data
The following are typical data used in the description of a
barrier:
28 V, 300 Ohm, 93 mA. These values relate to the maximum
voltage, the minimum value of the built-in resistance and the
resulting maximum current.
The maximum voltage stated is not representative of the
operating range, it is the maximum value that can be attained
in a failure case, before the fuse responds. The resistance
value is not identical to the maximum series resistance. These
values merely provide an indication of the maximum values
that can apply in the case of a failure.
Series resistance
This is the resistance that can be measured between the two
ends of a barrier channel. It is obtained from the sum of the
resistance R and resistance value of the fuse at an ambient
temperature of 20 C.
Polarity
Zener barriers are available in various versions. On Zener
barriers for positive polarities the anodes of the Zener diodes
are grounded. On barriers for negative polarities it is the
cathodes which are grounded. On barriers for alternating
polarities, interconnected Zener diodes are employed and one
side is grounded. These can be used for both alternating
voltage signals and direct voltage signals.
Maximum voltage in the intrinsically safe circuit. (Uz)
This is the maximum value of voltage that can occur in the
intrinsically safe circuit in the failure case.
Maximum current in the intrinsically safe circuit (Ik)
1.6 How to select the correct barrier
For very many applications the standard solutions are given in
this catalogue, in the section on Example Applications.
However, in the event that a particular application has not been
covered, the following information may be helpful.
1. First decide whether it will be necessary to have a floating
circuit, or whether the intrinsically safe circuit can be
connected directly to ground. Check whether any existing
instrumentation is grounded. If the answer is yes, then
check whether additional grounding could lead to faults.
Bear in mind that the floating circuit offers a better common-
mode rejection characteristic than the grounded circuit. On
the other hand, it is more expensive. If a floating circuit is
employed, the barriers will normally resist a ground fault.
2. Select the required polarity. This is either determined by the
circuit itself, or by any other existing grounds in the circuit. In
most applications barriers for positive polarities are used. In
order to achieve greater system standardisation, barriers
suitable for alternating polarities can be used in place of
unipolar ones.
3. Decide the nominal voltage of the Zener barrier. Then
determine the maximum output voltage of the device in the
safe area during normal operation. Normally the required
value is the next highest nominal voltage of a Zener barrier.
If these values are close together, it could be that the
Subject to reasonable modifications due to technical advances.
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This is the maximum current that can flow in the intrinsically
safe circuit in the failure case.
Maximum input voltage (max. Uin)
The maximum voltage (correct polarity) that can be applied
between the contacts in the safe area and the ground without
the fuse responding. This value is determined for an open
intrinsically safe circuit and an ambient temperature of 20 C.
Input voltage (Uin at 10 (1) A)
The maximum voltage (correct polarity) that can be applied
between the contacts in the safe area and the ground at a
defined leakage current (as a rule 10 A). This is the upper
value of the recommended operating range.
Maximum connectable external capacitance Cmax
This is the maximum capacitance that can be connected to the
terminals of the barrier intrinsically safe circuit. This value is
determined from the sum of the wiring capacitance and the
input capacitance of the field device.
Maximum connectable external inductance Lmax
This is the maximum inductance that can be connected to the
terminals of the barrier intrinsically safe circuit. The value is
determined from the sum of the inductance of the wiring and
the input inductance of the field device.
Note:
The designations of the values given in the specifications
above are not those of the relevant standards, but those
specified on certificates of conformity (e. g. in EN 60079-14,
Section 3, IK is now IO).
recommended operating range of the Zener barrier is
exceeded. The consequence of this is that the leakage
current will be greater than 10 A. In this case a barrier with
a higher nominal voltage should be used. The leakage
current is determined for an open intrinsically safe circuit
and this then represents the maximum value at the given
voltage.
4. Take account of the maximum series resistance of the
Zener barrier and its effect on the intrinsically safe circuit.
Make sure that this resistance does not cause an
inadmissibly high loss of voltage. In circuits having high
resistance - usually when voltage signals are being
transferred - this resistance is not relevant. If for example a
barrier has a max. series resistance of 1 kOhm, then the
resulting error is 0.1 %, if the input resistance of the
connected device is 1 MOhm.
5. Check whether or not the field device must be certificated for
use in the hazardous area. If certification is necessary,
check what the prerequisites are for permitting the field
device to be used in connection with a Zener barrier.
6. What is the overall length of the cabling between the voltage
supply and the field device? Note the number of conductors
in the system!
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Copyright Pepperl+Fuchs, Printed in Germany
 Zener barriers - operating instructions
How to select the correct barrier
7. The following points have to be clarified if special field
devices are used.
If the field device is a 4 mA ... 20 mA transmitter: What load
in ohms can be connected to the transmitter so that it can
attain 20 mA as before?
If the field device is a current/pressure converter: What load
can be connected to the controller card so that it can attain
20 mA as before?
If the field device is a transmitter: How high is the load in the
safe area? (typically, resistances of up to 250 Ohm are used
in the controller)

Z ...

Barrier with replaceable back-up fuse

The introduction of a replaceable back-up fuse ahead of the arranged that the outer fuse will respond before the inner,
integrated fuse provides protection against faults which could innaccessible fuse. The fuses used are specially intended for
occur during the commissioning of the system. It is always use on barriers.

Type Max. series Uin Uin Fuse rating External fuse Fuse supplied
Channels resistance at 10 A max by LITTLEFUSE
Ohm V V mA mA
Z715.F 1 106 13 13.6 100 63 217,063
Z728.F 1 327 27 28 80 50 217,05
Z728.H.F 1 250 27 28 80 50 217,05
Z765.F 2 106 13 13.6 100 63 217,063
106 13 13.6 100 63
Z779.F 2 327 27 28 80 50 217,05
327 27 28 80 50
Z779.H.F 2 250 27 28 80 50 217,05
250 27 28 80 50
Z787.F 2 327 27 28 80 50 217,05
36 + 0.9V 27 28 80 50
Z787.H.F 2 250 27 28 80 50 217,05
25 + 0.9V 27 28 80 50
Z960.F 2 64 6.5 9.5 80 50 217.05
64 6.5 9.5 80 50
Z961.F 2 106 6.5 8.1 160 100 217.1
106 6.5 8.1 160 100
Z966.F 2 166 10 11.7 100 63 217.063
166 10 11.7 100 63
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Zener barriers - operating instructions
How to select the correct barrier

Type Nominal data Ex-characteristics for [EEx ia] IIC Certification no.

+ ve - ve a.c. V W Uz (V) Rmin (W) IK(mA) Pmax(W) Cmax (F) Lmax (mH) L/R Ratio
Z705 Z805 5 10 4.94 9.8 504 0.62 100 0.14 57 BAS 01 ATEX 7005
Z905 5 10 4.98 9.8 499 0.61 100 0.14 57 BAS 01 ATEX 7005
Z710 Z810 10 50 9.56 49 195 0.47 3 0.86 73 BAS 01 ATEX 7005
Z910 10 50 9.94 49 203 0.50 3 0.86 73 BAS 01 ATEX 7005
Z810.CL 10 50 9.56 49 195 0.47 3 0.86 73 BAS 01 ATEX 7005

Z713 Z813 15.75 22 15.75 21.8 723 2.84 0.48 0.076 12.5 BAS 01 ATEX 7005

Z715 Z815 15 100 14.7 98 150 0.55 0.58 1.3 64 BAS 01 ATEX 7005
Z715.F Z815.F 15 100 14.7 98 150 0.55 0.62 1.45 67 BAS 01 ATEX 7096
Z915 15 100 15.0 98 153 0.57 0.58 1.3 64 BAS 01 ATEX 7005
Z715.1K 15 1k 14.7 980 15 0.06 0.58 144 570 BAS 01 ATEX 7005
Z915.1K 15 1k 15 980 15 0.06 0.58 144 570 BAS 01 ATEX 7005

Z722 Z822 22 150 22 147 150 0.82 0.17 1.45 45 BAS 01 ATEX 7005
Z728 Z828 28 300 28 301 93 0.65 0.083 3.05 56 BAS 01 ATEX 7005
Z728.H Z828.H 28 240 28 235 119 0.83 0.083 1.82 44 BAS 01 ATEX 7005
Z728.F Z828.F 28 300 28 301 93 0.65 0.083 4.21 55 BAS 01 ATEX 7096
Z728.H.F Z828.H.F 28 240 28 235 119 0.83 0.083 2.59 44 BAS 00 ATEX 7096
Z728.CL Z828.CL 28 300 28 301 93 0.65 0.083 3.05 56 BAS 01 ATEX 7005
Z928 28 300 28 301 93 0.65 0.083 3.05 56 BAS 01 ATEX 7005

Z755 Z855 5 10 4.94 9.8 504 0.62 100 0.14 57 BAS 01 ATEX 7005
5 10 4.94 9.8 504 0.62 100 0.14 57
4.94 4.9 1008 1.25 100 0.03 22

Z955 5 10 4.89 9.8 499 0..61 100 0.14 57 BAS 01 ATEX 7005
5 10 4.89 9.8 499 0.61 100 0.14 57
9.78 4.9 998 1.22 3.3 0.03 22

Z757 Z857 7 10 7.14 9.8 729 1.3 13.5 0.07 28 BAS 01 ATEX 7005
7 10 7.14 9.8 729 1.3 13.5 0.07 28
7.14 4.9 1457 2.6 13.5 0.02 11
Z961 9 100 8.7 98 89 0.19 4.9 4.69 182 BAS 01 ATEX 7005
9 100 8.7 98 89 0.19 4.9 4.69 182
17.4 98 178 0.39 0.346 1.14 72
Z961.F 9 100 8.7 98 89 0.192 4.9 4.39 176 BAS 01 ATEX 7096
9 100 8.7 98 89 0.192 4.9 4.39 176
17.4 98 178 0.384 0.31 1.07 67
Z961.H 9 360 8.7 352.8 25 0.05 4.9 57 613 BAS 01 ATEX 7005
9 360 8.7 352.8 25 0.05 4.9 57 613
17.4 355 49 0.11 0.346 15.2 249

Z764 Z864 12 1k 11.6 980 12 0.03 1.41 240 1.0 BAS 01 ATEX 7005
12 1k 11.6 980 12 0.03 1.41 240 1.0
11.6 490 24 0.06 1.41 61 360

Z964 12 1k 12 980 12 0.04 1.41 240 1.0 BAS 01 ATEX 7005

12 1k 12 980 12 0.04 1.41 240 1.0
24 490 24 0.08 0.125 61 360

Z765 Z865 15 100 14.7 98 150 0.55 0.58 1.3 64 BAS 01 ATEX 7005
15 100 14.7 98 150 0.55 0.58 1.3 64
14.7 49 300 1.1 0.58 0.32 22
Z765.F Z865.F 15 100 14.7 98 150 0.55 0.62 1.45 67 BAS 01 ATEX 7096
15 100 14.7 98 150 0.55 0.62 1.45 67
14.7 49 300 1.1 0.62 0.32 22
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 Zener barriers - operating instructions
How to select the correct barrier

Max. Circuit diagram

end-to-end Uin Uin Fuse rating see circuit Hazardous area Safe area see note 2
resistance at 10 A max diagram No. connections connections
W V V mA
18.18 0.9 (1 A) 4.8 250 1), 2) 1)
18.18 0.9 (1 A) 4.7 250 3)
56 6.5 8.9 100 1), 2) 1 CL 8
56 6.5 9.3 100 3)
x3
63 + 2 V 6.5 8.9 100 1), 2)

29 13.7 14.6 160 2 7

+VE type
107 13.0 13.6 100 1), 2)
2)
119 13.0 13.8 63
107 13.0 14.0 100 3)
1 CL 8
1025 13.0 13.6 100 3)
1025 13.0 14.0 100 1), 2) x3
166 19.0 20.1 50 1), 2)
2 7
327 26.5 28.0 50 1), 2) -VE type
250 26.5 28.0 80
338 26.5 28.0 50 3)
261 26.5 28.0 50
1 8
342 + 2 V 26.5 28.0 50 1), 2)
327 26.0 27.6 50 3) x3
x3
18.18 0.9 (1 A) 4.8 250 4), 5) A1
2 7
18.18 0.9 (1 A) 4.8 250 AC type A2
B
4)
18.18 0.9 (1 A) 4.7 250 6) A1
18.18 0.9 (1 A) 4.7 250 1 8 A2
x3 B
2 7
15.5 6.0 6.9 200 4), 5) A1
15.5 6.0 6.9 200 3 6 A2
x3
B
106 6.5 8.1 100 6) 4 5 A1
+VE type
106 6.5 8.1 100 A2
5 B
)

113 6.5 8.0 100 A1

1 8
380 6.5 8.1 50 A2
x3
2 7 B
380 6.5 8.1 50 6) A1
380 6.5 8.1 50 3 6 A2
x3
B
4 5
1033 10.0 11.0 50 4), 5) -VE type A1
1033 10.0 11.0 50 A2
6)
B

1033 10.0 11.7 50 6) 1 8 A1

x3
1033 10.0 11.7 50 x3 A2
2 7
B

107 13.0 13.6 100 4), 5) 3 x3 6 A1

107 13.0 13.6 100 x3 A2
4 5
AC type B
119 13.0 13.9 63 A1
119 13.0 13.9 63 A2
B
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Zener barriers - operating instructions
How to select the correct barrier

Type Nominal data Ex-characteristics for [EEx ia] IIC Certification no.

+ ve - ve a.c. V W Uz (V) Rmin (W) IK(mA) Pmax(W) Cmax (F) Lmax (mH) L/R Ratio
Z966 12 150 12 147 82 0.24 1.41 5.52 147 BAS 01 ATEX 7005
12 150 12 147 82 0.24 1.41 5.52 147
24 73.5 164 0.48 0.125 1.38 57

Z966.F 12 150 12 147 82 0.24 BAS 01 ATEX 7096

12 150 12 147 82 0.24
24 73.5 164 0.49
Z966.H 12 75 12 73.5 164 0.49 1.41 1.38 75 BAS 01 ATEX 7005
12 75 12 73.5 164 0.49 1.41 1.38 75
24 36.5 328 0.98 0.125 0.33 36

Z772 Z872 22 150 22 147 150 0.82 0.17 1.45 45 BAS 01 ATEX 7005
22 150 22 147 150 0.82 0.17 1.45 45
22 73.5 300 1.64 no approval for IIC

Z778 Z878 28 600 28 607 46 0.32 0.083 17.2 109 BAS 01 ATEX 7005
28 600 28 607 46 0.32 0.083 17.2 109
28 303.5 93 0.65 0.083 3.05 42
Z779 Z879 28 300 28 301 93 0.65 0.083 3.05 56 BAS 01 ATEX 7005
28 300 28 301 93 0.65 0.083 3.05 56
28 150.5 186 1.3 no approval for IIC
Z779.H Z879.H 28 240 28 235 119 0.83 0.083 1.82 44 BAS 01 ATEX 7005
28 240 28 235 119 0.83 0.083 1.82 44
28 117.5 238 1.67 no approval for IIC
Z779.F Z879.F 28 300 28 301 93 0.65 0.083 4.21 55 BAS 00 ATEX 7096
28 300 28 301 93 0.65 0.083 4.21 55
Z779.H.F Z879.H.F 28 240 28 235 120 0.83 0.083 2.59 44 BAS 01 ATEX 7096
28 240 28 235 120 0.83 0.083 2.59 44

Z796 Z896 26.6 320 26.6 314 85 0.56 0.094 5.14 64 BAS 01 ATEX 7005
20.5 415 20.5 407 50 0.26 0.204 14.6 138
26.6 177 135 0.82 0.094 2.05 34

Z788 Z888 28 300 28 301 93 0.65 0.083 3.05 56 BAS 01 ATEX 7005
10 50 9.56 49 195 0.47 3.0 0.86 73
28 42 288 0.87 0.083 0.32 26
Z788.H Z888.H 28 240 28 235 119 0.83 0.083 1.82 44 BAS 01 ATEX 7005
10 50 9.56 49 195 0.47 3.0 0.86 73
28 40 314 1.0 0.083 0.26 25
Z788.R 28 300 28 301 93 0.65 0.083 3.05 56 BAS 01 ATEX 7005
10 50 9.56 49 195 0.47 3.0 0.86 73
28 42 288 0.87 0.083 0.32 26

Z786 Z886 28 Diode 28 Diode 0 0.0 0.083 BAS 01 ATEX 7005

28 Diode 28 Diode 0 0.0 0.083
28 Diode 28 Diode 0 0.0 0.083

Z787 Z887 28 300 28 301 93 0.65 0.083 3.05 56 BAS 01 ATEX 7005
28 Diode 28 Diode 0 0 0.083
28 301 93 0.65 0.083 3.05 56
Z787.H Z887.H 28 240 28 235 119 0.83 0.083 2.82 44 BAS 01 ATEX 7005
28 Diode 28 Diode 0 0 0.083 see note 1
28 235 119 0.83 0.083 2.82 44
Z787.F Z887.F 28 300 28 301 93 0.65 0.083 4.21 55 BAS 01 ATEX 7096
28 Diode 28 21.8 Diode 0 0.083
28 301 93 0.65 0.083 4.21 55
Z787.H.F Z887.H.F 28 240 28 235.2 120 0.83 0.083 2.59 44 BAS 01 ATEX 7096
05/23/03

28 Diode 28 14.7 Diode 0 0.083

28 235.2 120 0.83 0.083 2.59 44
Date of issue

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 Zener barriers - operating instructions
How to select the correct barrier

Max. Circuit diagram

end-to-end Uin Uin Fuse rating see circuit Hazardous area Safe area see note 2
resistance at 10 A max diagram No. connections connections
W V V mA
166 10.0 11.7 50 6) 4) A1
166 10.0 11.7 50 A2
1 8
B
x3
2 7
169 10.0 11.9 63 A1
169 10.0 11.9 63 3
A2
6
x3 B
82 10.0 11.7 100 6) 4 5 A1
+VE type
82 10.0 11.7 100 A2
5
)
B
1 8
166 19.0 20.1 50 4), 5) A1
x3
166 19.0 20.1 50 2 7 A2
B
3 6
646 26.5 28.0 50 4), 5) x3 A1
646 26.5 28.0 50 4 5 A2
-VE type
B
6)
327 26.5 28.0 50 4), 5) A1
327 26.5 28.0 50 1 8 A2
x3 B
2 x3 7
250 26.5 28.0 80 4), 5) A1
250 26.5 28.0 80 A2
3 x3 6
B
x3
338 26.5 28.0 50 4 5
AC type
338 26.6 28.0 50
264 26.5 28.0 50 7)
264 26.5 28.0 50
1 8
340 24.0 25.1 50 4), 5) x3 A1
2 7
437 18.0 19.5 50 A2
3 6 B
x3
327 26.5 28.0 50 4), 5) 4 5 A1
64 6.5 9.1 50 AC type A2
All diodes are turned 180 B
for the -VE version.
250 26.5 28.0 80 4), 5) A1
64 6.5 9.1 80 8) A2
B
1 8
327 26.5 28.0 50 7) A1
x3
64 9.1 50 2 7 A2
B
3 6
x3
36 + 0.9 V 26.5 28.0 50 8) A1
4 5
36 + 0.9 V 26.5 28.0 50 A2
B
All diodes are turned 180
for the -VE version.
327 26.5 28.0 50 9) A1
36 + 0.9 V 26.5 28.0 50 9) A2
B
1 8
250 26.5 28.0 80 9) A1
x3
25+ 0.9 V 26.5 28.0 80 2 7 A2
B
338 26.5 28.0 50 3 6 A1
x3
46+ 0.9 V 26.5 28.0 50 4 5
A2
B
264 26.5 28.0 50 All diodes are turned 180 A1
05/23/03

39+ 0.9 V 26.5 28.0 50 for the -VE version. A2

B
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Zener barriers - operating instructions
How to select the correct barrier

Type Nominal data Ex-characteristics for [EEx ia] IIC Certification no.

+ ve - ve a.c. V W Uz (V) Rmin (W) IK(mA) Pmax(W) Cmax (F) Lmax (mH) L/R Ratio
Z960 10 50 9.94 49 203 0.50 3;0 0.86 73 BAS 01 ATEX 7005
10 50 9.94 49 203 0.50 3;0 0.86 73
9.94 24.5 406 1.0 3;0 0.19 26
Z960.F 10 50 9.94 98 203 0.51 2.63 0.82 69 BAS 01 ATEX 7096
10 50 9.94 49 203 0.51 2.63 0.82 69
9.94 49 406 1.02 2.63 0.82 25

Z965 15 100 15 98 153 0.57 0.58 1.3 64 BAS 01 ATEX 7005

15 100 15 98 153 0.57 0.58 1.3 64
15 49 306 1.14 0.58 0.29 20

Z967 17 120 16.8 117 143 0.60 0.38 1.63 60 BAS 01 ATEX 7005
17 120 16.8 117 143 0.60 0.38 1.63 60
16.8 58 286 1.20 0.38 0.24 21

Z972 22 300 22 301 73 0.40 0.17 6.95 90 BAS 01 ATEX 7005

22 300 22 301 73 0.40 0.17 6.95 90
22 150 146 0.80 0.17 1.45 35

Z978 28 600 28 607 46 0.32 0.083 17.2 109 BAS 01 ATEX 7005
28 600 28 607 46 0.32 0.083 17.2 109
28 304 93 0.65 0.083 3.05 42

Z954 4.5 12 4.5 11.76 383 0.43 100 0.24 81 BAS 01 ATEX 7005
4.5 12 4.5 11.76 383 0.43 100 0.24 81
4.5 12 4.5 11.76 383 0.43 100 0.24 81
9.0 5.88 765 0.86 4.9 0.068 41
9.0 3.92 1150 1.29 4.9 0.03 27
9.0 17.64 510 1.15 4.9 0.12 30

Dummy
Z799

05/23/03
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 Zener barriers - operating instructions
How to select the correct barrier

Max. Circuit diagram

end-to-end Uin Uin Fuse rating see circuit Hazardous area Safe area see note 2
resistance at 10 A max diagram No. connections connections
W V V mA
64 6.5 9.5 50 10) 10) A1
64 6.5 9.5 50 A2
1 8 B
x3 A1
2 7
75 6.5 9.7 50 A2
75 6.5 9.7 50 B
3 x3 6
115 13.0 14.2 50 10) A1
4 5
115 13.0 14.2 50 A2
B

136 15.0 16.2 50 10) 11) A1

136 15.0 16.2 50 A2
1 8
B
x3
327 19.0 20.9 50 10) 3 6 A1
327 19.0 20.9 50 x3 A2
2 7 B
x3
646 26.0 27.6 50 10) A1
4 5
646 26.0 27.6 50 A2
B

27.27 0.9 (1 A) 4.9 50 11) A1

27.27 0.9 (1 A) 4.9 50 A2
27.27 0.9 (1 A) 4.9 50 A3
B
B
C

1 8

2 7

3 6

4 5

Note 1: Note 2:
Zener barriers type Z787H and Z887H have channels with A1, A2 and A3 are separate channels.
diode returns. B: Two channels in parallel circuit with a ground connection.
The Ex-terminals for the channels with diode returns should be C: Two channels in series circuit without a ground return.
regarded as 28 V voltage sources.
The 28 V must be considered as the theoretical maximum up
to which a capacitive load can be applied to the Ex-terminals
due to the leakage current of the diode return. This voltage is
only used in calculating the load capacitance.
05/23/03
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 Zener barriers - operating instructions
Application examples

1.7 Application examples

Temperature measurement

Hazardous area Safe area

Z705
Not grounded 1 8
CL

Temperature
x3 monitoring
or control
2 7

The simplest and most favourably priced solution is a single- device is not grounded in the safe area. The system is
channel Zener barrier. It should be noted, however, that the approved for [EEx ia] IIC.

Hazardous area Safe area

Z960

1 8

x3 x3
2 7 Temperature
monitoring
3 6
or control
4 x3 5

The use of a two-channel barrier prevents the direct ground This circuit arrangement prevents the occurrence of mutual
connection of the intrinsically safe circuit. Grounding only takes interference between the various circuits. The system is
place in the event of a fault, when the Zener diodes conduct. approved for [EEx ia] IIC.

Hazardous area Z961 Safe area

1 8
x3
2 x3 7

3 6
x3
4 x3 5

Z961

1 8
x3
2 x3 7

3 6
x3
4 x3 5
05/23/03

The illustration shows the set up for a temperature This is the best option when the intention is to suppress the
measurement with a 4-wire Pt100. None of the 4 wires is influence of the end-to-end resistance of the barrier on the
connected directly to ground. The complete system is therefore measuring accuracy as far as possible.
Date of issue

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 Zener barriers - operating instructions
Application examples
Temperature measurement

Hazardous area Safe area

Z954

1 8
x3
3 x3 6
x3
2 x3 7 Test circuit
x3
4 x3 5

The circuit arrangement shows the connection of a Pt100 in 3- end-to-end resistances, so that the resulting error is restricted
wire technology, using the 3-channel Zener barrier Z954. The to a minimum. The system is approved for [EEx ia] IIC.
whole system is quasi ground-free. All 3 barriers have identical

Hazardous area Z961 Safe area

1 8
x3
2 x3 7

3 6
x3
4 x3 5

Z954

1 8
x3
3 x3 6
x3
2 x3 7
x3
4 x3 5

Receiver with
galvanically
isolated inputs
Z954

1 8
x3
3 x3 6
x3
2 x3 7
x3
4 x3 5

The circuit consists of a system of a maximum of seven The Z954s have been selected due to their high end-to-end
Pt100s. The Pt100s are connected in series to a constant resistance. Due to the high input resistance of the receiver, the
current source. Each voltage signal is transferred to a receiver high end-to-end resistance has practically no effect on the
via a Z954. accuracy of measurement.
05/23/03
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 Zener barriers - operating instructions
Application examples
0 mA 20 mA/4 mA 20 mA transmitter

Hazardous area Safe area

Z728

1 8
CL

x3 A

2 7

If a ground-free power supply is available, the use of a single-
channel Zener barrier, grounded in the safe area, represents
the simplest and most economical solution. The ammeter can
be used in combination with a recording instrument, a trip
amplifier, or a 250 Ohm resistance, or replaced by these
devices. In so doing, the overall resistance of the arrangement
must be taken into account. The working range of the barrier
caters for an input voltage of up to 27 V. For each built-in
250 Ohm resistance the output voltage of the power supply
can be increased by 1 V. By using a 250 Ohm resistance and a
supply voltage of 28 V, a source of 16.5 V at 20 mA is available
to the transmitter in the hazardous area. The internal voltage
drop across the barrier is then 6.5 V. The system is approved
for [EEx ia] IIC.

Hazardous area Safe area

Z788

1 8
x3
2 7

3 6
4 x3 5
A

With this 2-channel Zener barrier, it is possible to supply a ammeter for converting the current signal into a 1 V 5 V
number of circuits with one source. All the wiring is quasi voltage signal is replaced by a 250 Ohm resistance, then
ground-free. The maximum voltage supply is 27 V. The internal 14.2 V are available at the field device. The system is
voltage drop across the barrier is 7.8 V at 20 mA, so that approved for [EEx ia] IIC.
19.2 V are available for the field device and ammeter. If the
05/23/03
Date of issue

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 Zener barriers - operating instructions
Application examples
0 mA 20 mA/4 mA 20 mA transmitter

Hazardous area Safe area

Z788.R

1 8
x3
2 7

3 6
4 x3 5
V

This system can be used if the field device requires a relatively barrier. Thus a voltage of 15.5 V is available at the field device
high voltage. A 250 Ohm resistance is connected in parallel if the voltage supply is 27 V. The system is approved for
with the Ex-output of the 10 V/50 Ohm output of this 2-channel [EEx ia] IIC.
Hazardous area Safe area
Z787

1 8
x3
2 7
3 6
A

4 x3 x3 5

The combination of a 28 V, 300 Ohm and a 28 V barrier with voltage drop. The reason for this is the diode return. The
diode return is the solution for applications with 3-wire system is approved for [EEx ia] IIC.
transmitters. Special attention must be paid here to the internal
05/23/03
Date of issue

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 Zener barriers - operating instructions
Application examples
SMART transmitter

Hazardous area Safe area

Z787

1 8
x3
2 7

3 6
4 x3 5
A

The simplest possible solution is the use of a 2-channel Zener The data transfer is bidirectional, so that a non-certificated
barrier with 28 V, 300 Ohm and 28 V diode return. If a communicator can be connected and used in the the safe area.
regulated power supply unit provides an output voltage of 27 V, The system is approved for [EEx ia] IIC.
13.9 V will be available to the transmitter and wiring in the Ex-
area.
Strain gauge bridges

Hazardous area Z966 Safe area

1 8
x3
2 x3 7

3 6
x3
4 x3 5

Z964

1 8
x3
2 x3 7 +

3 6 -
x3
4 x3 5

Z964

1 8
x3
2 x3 7
Signal
3 6
x3
4 x3 5

The strain gauge bridge is supplied via the Z966. The Z966 obtain the best possible accuracy of measurement.
05/23/03

enables a 350 Ohm strain gauge bridge to be supplied with The millivolt signal is transferred to the safe area via the Z964.
8 V. The voltage feedback via the Z964 can be dispensed with, The system is approved for [EEx ia] IIC.
although in practice most applications require this feedback to
Date of issue

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 Zener barriers - operating instructions
Application examples
Wire strain gauges

Hazardous area Z966 Safe area

1 8
x3
2 x3 7

3 6
x3
4 x3 5

Z966

1 8
x3
2 x3 7

3 6
x3
350 Ohm 4 x3 5

Z964

1 8 Sensor + - 0 +
x3
350 Ohm 2 x3 7

3 6
x3
4 x3 5 Sensor -

Z964
350 Ohm
1 8
x3
2 x3 7

3 6
x3
4 x3 5

If more than one strain gauge bridge is to be supplied from a Both channels of these Zener barriers are arranged in parallel
common power supply (in the example shown above there are in order to reduce the end-to-end resistance. This arrangement
three), a possible solution is to supply them via two Z966s, as provides 8 V to the bridges if the voltage supply is 20 V. The
shown. system is approved for [EEx ib].
05/23/03
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 Zener barriers - operating instructions
Application examples
Potentiometric position detection

Hazardous area Safe area

Z960

1 8

x3 x3
2 7

3 6
4 x3 5
V

Applications in which the accuracy is not critical can be side would have an effect on the voltage signal and would have
satisfied as shown above. The intrinsically safe circuit has a to be taken into account. The system is approved for [EEx ia]
direct connection to ground. An additional resistance on this IIC.

Harzardous area Safe area

Z715

1 8
CL

x3

2 7

Z715.1K

1 8
CL

x3

2 7
Signal

Z715.1K

1 8
CL

x3

2 7

If greater accuracy is required, a 4-wire solution must be signal to the receiver. The supply voltage in the example above
applied. The Z715 Zener barrier transfers the power supply to could be 13 V.
the potentiometer, whilst two Z715.1K barriers transfer the
05/23/03
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 Zener barriers - operating instructions
Application examples
Solenoid valves

Hazardous area Safe area

Z728

1 8
CL

x3

2 7

The simplest and most economical solution is a single channel supply voltage of 27 V, 4 V would remain for the voltage drop
Zener barrier, with the power supply grounded on its safe side. through the field wiring. The system is approved for
If the valve requires 30 mA at a minimum 12 V, then at a [EEx ia] IIC.

Hazardous area Safe area

Z787

1 8

4 x3 5

3 x3 6
2 7

If the switch is in parallel circuit with the nominal mains voltage, paid to the voltage drop in the barrier, since the diode return
it is usual to use a barrier combination of 28 V, 300 Ohm and a causes an additional loss of voltage. The system is approved
28 V diode return. In this solution, special attention has to be for [EEx ia] IIC.
Switch status

Hazardous area Safe area

Z787
Z887
1 8

4 x3 5

3 x3 6
2 7

In the traditional method of switch status detection, the switch
is provided with noble metal contacts suitable for low voltages
and currents. A ground fault in any field wire leaves the relay in
the de-energised state, despite the switch being closed. This
05/23/03
At a nominal voltage of up to 27 V, a typical coil with 12 V and
approx. 350 Ohm can be used to match the power. The Zener
barrier is approved for [EEx ia] IIC. Negative polarities can be
accommodated with the Z887.

problem is solved by the use of quasi ground-free wiring.

Date of issue

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 Zener barriers - operating instructions
Application examples
Pulse transmission and flow measurement

Hazardous area Safe area

Z728
Flow meter with
1 8
pulse output CL

x3 Output

2 7

The simplest method of flow measurement, with or without a generates sinusoidal signals, e. g. an inductive sensor, a Zener
pre-amplifier, is illustrated in the circuit above. The flow meter barrier for alternating polarities can be used, for example the
sensor generates voltage or current pulses, which are Z928. The Zener barrier is approved for [EEx ia] IIC.
transmitted to the safe area via the Z728. If the sensor

Hazardous area Safe area

Z787
Flow meter with
pulse output 1 8

4 x3 5
Output
3 x3 6
2 7

If the power supply to the flow meter is provided via a 28 V, (counter), consideration must be given to the fact that the high
300 Ohm barrier and ground, the signal can be transferred via signal is damped by the diode. The system is approved for
the diode return of the Z787. When selecting the receiver [EEx ia] IIC.
LED display

Hazardous area Safe area

Z728

1 8
CL

x3

2 7
05/23/03

The simplest and most economical solution is the single- barrier limits the flow of current through the LED to an
channel Zener barrier shown above. The nominal supply acceptable value. Otherwise a current-limiting resistor is
voltage is sufficiently low that the end-to-end resistance of the required. The system is approved for [EEx ia] IIC.
Date of issue

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 Zener barriers - operating instructions
Application examples
LED display

Hazardous area Safe area

Z728.CL

1 8
CL

x3

2 7

The circuit shown above does not require a current limiting
resistor, since the Z728.CL limits the current electronically to a
maximum of 40 mA. At a supply voltage of 18 V 27 V a
current of 40 mA flows in the intrinsically safe circuit. This
Smoke and fire alarms
current reduces at lower nominal supply voltages. To special
order, the Z728.CL can be supplied with lower current-limiting
values. The system is approved for [EEx ia] IIC. The Z828.CL
is also suitable for negative polarities.

Hazardous area Safe area

Z728 Output

1 8
CL

x3
I
2 7

The simplest and most cost-effective solution is shown in the The current applied to the detector is sufficient to operate the
illustration above. With a 24 V nominal supply voltage, there is LED display with sufficient brightness. The system is approved
an off-state current of approx. 4 mA. When the detector for [EEx ia] IIC.
responds, the current increases to approx. 25 mA or greater.

Hazardous area Safe area

Z787 Output

1 8

4 x3 5
I

3 x3 6
2 7
05/23/03

The system shown above is comparable to the Z728 and is this application the intrinsically safe circuit is quasi ground-free.
also relatively inexpensive. The Z787 is a 2-channel device. In The system is approved for [EEx ia] IIC.
Date of issue

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 Zener barriers - operating instructions
Application examples
Audible alarms

Hazardous area Safe area

Z728

1 8
CL

x3

2 7

Audible alarms operate at relatively high voltages and low barriers. The simplest solution is the circuit shown above.
currents. They are approved for use with various Zener
I/P converters

Hazardous area Safe area

Z787

1 8
x3
P 2 7

I 3 6
4 x3 5

The simplest and most cost-effective solution is a single- 900 Ohm if the voltage supply is 27 V. In practice, however, the
channel Zener barrier. The nominal supply control voltage voltage values are lower, so that the field circuit normally has a
must either be ground-free or connected to the negative output resistance of 300 Ohm.
to earth. In theory, the field circuit can have a resistance of 05/23/03
Date of issue

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